Multi-station die-less packaging machine

Abstract

A new computerized control system designed for packaging machines. This control system can be installed on any dieless packing machine. The advances achieved by this control system are: High speeds are achieved by synchronizing the machine index cycle and tooling controls, permitting the prestart of tooling before the end of the index cycle; because the motor speed is monitored and profiled by the computer continuously, faster machine speeds can be achieved while maintaining the minimum machine jerk; total index time savings; diagnostics which dramatically reduce machine down time as a user friendly hard-copy print out is produced describing and pinpointing locations of malfunctions in the timers, tooling, and motor performance; access to all timer control settings through easy to use thumbwhell switches. In addition, a new arrangement of the tooling stations is used, allowing for the increase of per cycle capacity several times the capacity of the prior art. The sealing station includes an initial sealing substation where no vacuum operation is performed, and a final sealing substation where a vacuum operation of considerably reduced requirements of time is carried out.

What is claimed is: 
     
       1. In a die-less product-packaging machine comprising a film-storage means for unwinding film, a film-forming station where packages are formed for storing products, a product loading-station where products are placed into the packages formed at said film-forming station, a heat-sealing station where the product-loaded formed-packages are covered with a cover-sealing film, and means for indexing the film from one said station to the next, said means for indexing comprising conveyor means and a motor means for moving said conveyor means, the improvement comprising: computer-control means for controlling the operation of said means for indexing and for actuating said film-forming station and said heat-sealing station, said computer-control means actuating each of said film-forming station and said heat-sealing station in direct relationship to the position of said motor means; said computer control means actuating each said film-forming station and said heat-sealing station during operation of said motor means while said conveyor means is still conveying, whereby time-saving and greater productivity is achieved.   
     
     
       2. The improvement according to claim 1, wherein each of said stations comprises work-station tool means reciprocally movable toward the film for operation thereon, and away from the film after said operation thereon, said computer-control means moving said work-station tool means toward the film for a specified time interval before the film has been completely indexed by said means for indexing, so that said time-saving is achieved, each said work-station tool means being moved away from said film before said means for indexing has started conveying said film. 
     
     
       3. The improvement according to claim 2, wherein said film-forming station comprises a first substation comprising three spaced-apart molds, the space between adjoining said molds being approximately equal to the width of a said mold; and a second substation comprising two spaced-apart molds; said two molds of second substation operating on the portions of the film-web not formed into a package at said first substation. 
     
     
       4. The improvement according to claim 3, wherein each said mold comprises one linear row of a plurality of mold-receptacles, each said mold-receptacle having a vacuum-forming opening by which said work-station tool means of said film-forming station may form a portion of said film positioned therein into a package. 
     
     
       5. The improvement according to claim 1, wherein said sealing station comprises a first initial-seal substation for sealing most of the perimeter of the package via a cover-film, and a second final-seal substation spaced downstream from said first initial-seal substation for finishing the seal of the package, said sealing work-station tool means comprising seal substation comprising sealing means for sealing only the portion of the cover-film not sealed to the package at said first initial-seal substation. 
     
     
       6. The improvement according to claim 2, wherein said sealing station comprises a first initial-seal substation for sealing most of the perimeter of the package via a cover-film, and a second final-seal substation spaced downstream from said first initial-seal substation for finishing the seal of the package, said sealing work-station tool means comprising vacuum-forming means at said final-seal substation, said final-seal substation comprising sealing means for sealing the portion of the cover-film not sealed to the package at said first initial-seal substation. 
     
     
       7. The improvement according to claim 2, wherein said film-forming station comprises a first substation, and a second substation located downstream of said first substation, each said first and second substation defining a plurality of mold-row locations, each said row-mold location extending widthwise in a direction transverse to the direction of movement of said means for conveying; each of said first substation and second substation comprising a plurality of linear molds spaced apart along the respective said substation such that a first set of alternate ones of said mold-rows has said linear molds associated therewith, and a second set of alternate ones of said mold-rows is free of said linear molds; one of said first sets defining odd-numbered mold-rows, and the other of said first sets defining even-numbered mold-rows. 
     
     
       8. The improvement according to claim 6, wherein said film-forming station comprises a first substation, and a second substation located downstream of said first substation, each said first and second substation defining a plurality of mold-row locations, each said row-mold location extending widthwise in a direction transverse to the direction of movement of said means for conveying; each of said first substation and second substation comprising a plurality of linear molds spaced apart along the respective said substation such that a first set of alternate ones of said mold-rows has said linear molds associated therewith, and a second set of alternate ones of said mold-rows is free of said linear molds; one of said first sets defining odd-numbered mold-rows, and the other of said first sets defining even-numbered mold-rows. 
     
     
       9. In a die-less packaging machine comprising film unwinding means, a web forming station, product loading station, vacuum and sealing means, film slitting and cross cutting means, top web film controlling means, eye marker searching means, molds for forming product-holding receptacles, and means for the raising and lowering of said molds at the forming and sealing stations, a motor having an indexing phase in which the motor causes the film web to traverse the work stations of the machine and a timer phase in which the film remains stationary and the tools and other functions are performed, wherein the improvement comprises: a computer controlling and monitoring system for said die-less packaging machine by which all mechanical activities of the said machine are controlled;   said computer system comprising means for activating and deactivating all functions of said machine associated with film unwinding, film-web forming tool-raising and lowering, sealing tool-lowering and raising, and heating and vacuum operations; said computer system also controlling the means for activating and deactivating slitter and cross cutting knives for separating finished products and means for acitvating and deactivating motor motion in the forward and reverse directions;   said computer controlling system comprising an output means through which error and diagnostic messages and system parameters may be communicated to operators of said machine; and   means of operator entry of operational parameters for said machine;   said computer system comprising means for detecting any and all error situations and malfunctions in tools, motor, and all other hardware components of the system and notifying operator of such circumstance, and of halting machine operations pending correction of said malfunction.   
     
     
       10. The computer control system according to claim 9, wherein said means of operator entry comprises a plurality of thumbwheel switches each of which can be set to any digit between 0 and 9, said thumbwheel switches being of significance individually or as conglomerations of individual digits representing multi-digit figures. 
     
     
       11. The control system according to claims 10, wherein said computer system comprises means for manually controlling slow motor movement for clearing mechanical jams, for resetting a new bottom web film position, for realigning top web film with bottom web film, and means for operating said motor in the reverse direction. 
     
     
       12. The system according to claims 9, wherein said computer system comprises means for performing diagnostic checks and for outputting results of said checks for the operator; said diagnostic means comprising means for motor position checks, motor velocity tests, motor index length test, motor synchronization position test, functional timer output test, and vacuum seal tests.   
     
     
       13. The system according to claim 9, wherein said computer system comprises means to issue forming and sealing tools up and tools down control signals at chosen times; said chosen times to be chosen as optimal moments wherein tools up signal is issued at a specified point while the motor is still advancing web film wherein said activation of tools up procedure will not be overly premature;   said signal activating the lowering of the tools down procedure administered by said control system during operations phase in advance of the motor indexing phase in a premature fashion allowing for earliest possible lowering of the tools such that forthcoming motor movement may begin immediately upon tools lowering sufficiently to allow the web film to be indexed without causing interference between tools and previously formed forms.   
     
     
       14. The system according to claim 9, wherein the operational parameters comprises maximum motor velocity and maximum motor acceleration at which the computer system is to operate the machine; said velocity and acceleration maximums being represented as percentages of the motor's total possible capacity. 
     
     
       15. The system according to claim 14, wherein the operating parameters entered by operator switches include the index length for the motor to advance the film web along the machine. 
     
     
       16. A method of forming a vacuum-package, comprising: (a) conveying forming-film to a first package-forming station;   (b) forming a plurality of rows of packages at said first package-forming station such that said rows of packages are spaced apart such that each row is spaced a distance from an adjoining row equal approximately to the width of a linear mold at the first substation;   (c) advancing the film to a second package-forming station;   (d) forming a plurality of rows of packages at said second package-forming station such that said rows of packages are spaced apart such that each row is spaced a distance from an adjoining row equal approximately to the width of a linear mold at the first substation, said rows being formed on those portions of the film web not formed into packages at said first package forming station.   
     
     
       17. The method according to claim 16, further comprising: (e) advancing the thus-formed packages to a loading station for loading products into the packages;   (f) advancing the loaded packages to an initial-sealing station where a cover-film seal is to be formed;   (g) placing a cover-film over the packages and partially-sealing the cover-film about a majority of the upper perimeter of each loaded package;   (h) advancing the loaded package to a final-sealing station;   (i) creating a vacuum in each of the loaded and partially-sealed packages, and sealing the portion of the package left unsealed during said step (g).   
     
     
       18. The method according to claim 17, further comprising controlling and synchronizing each of said steps (a) through (i) by computer control. 
     
     
       19. The method according to claim 18, wherein said step of controlling and synchronizing comprises initiating each of said steps (b), (d), (g) and (i) during said steps (a), (c), (e), (f) and (h), in order to save time of operation, each said initiation of said steps (b), (d), (g) and (i) being defined by the initial actuation of the work-station tools thereof. 
     
     
       20. The method according to claim 19, wherein said step of controlling and synchronizing comprises terminating each of said steps (b), (d), (g) and (i) before said steps (a), (c), (e), (f) and (h).